Dodge Caliber. Manual — part 1429
4. Remove the tape or plugs from the compressor
ports and the refrigerant line fittings.
5. Lubricate new rubber O-ring seals with clean refrig-
erant oil and install them and new gaskets onto the
refrigerant line fittings. Use only the specified
O-rings as they are made of a special material for
the R-134a system. Use only refrigerant oil of the
type recommended for the A/C compressor in the
vehicle.
6. Connect the A/C discharge line (5) and the A/C
suction line (6) to the A/C compressor (3).
7. Install the nuts (4) that secure the A/C suction and
discharge lines to the A/C compressor. Tighten the
nuts to 20 N·m (15 ft. lbs.).
8. Connect the engine wire harness (1) to the com-
pressor control valve (2).
9. Install the accessory drive belt (refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).
10. Install the splash shield onto the right side frame rail (refer to 23 - BODY/EXTERIOR/SPLASH SHIELD-RIGHT
SIDE RAIL - INSTALLATION).
11. Lower the vehicle.
12. Reconnect the negative battery cable.
CAUTION: Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the
A/C system. Failure to follow this caution will result in serious A/C compressor damage.
13. Evacuate the refrigerant system (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD
PROCEDURE - REFRIGERANT SYSTEM EVACUATE).
14. Charge the refrigerant system (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PRO-
CEDURE - REFRIGERANT SYSTEM CHARGE).
PM
PLUMBING
24 - 133
CONDENSER-A/C
DESCRIPTION
NOTE: A/C condenser with automatic transmission cooler shown. A/C Condenser without cooler similar.
The A/C condenser (1) is located in the front of the
engine compartment behind the grille. The A/C con-
denser is a heat exchanger that allows the high-pres-
sure refrigerant gas being discharged by the A/C
compressor to give up its heat to the air passing over
the condenser fins, which causes the refrigerant to
cool and change to a liquid state.
The A/C condenser is equipped with tapping blocks for
the A/C discharge line and the A/C liquid line (2) and
an integral automatic transmission cooler (3), when
equipped with an automatic transaxle.
OPERATION
When air passes through the fins of the A/C condenser, the high-pressure refrigerant gas within the A/C condenser
gives up its heat. The refrigerant then condenses as it leaves the A/C condenser and becomes a high-pressure
liquid. The volume of air flowing over the condenser fins is critical to the proper cooling performance of the A/C
system. Therefore, it is important that there are no objects placed in front of the radiator grille openings at the front
of the vehicle or foreign material on the condenser fins that might obstruct proper air flow. Also, any factory-installed
air seals or shrouds must be properly reinstalled following radiator or A/C condenser service.
The A/C condenser cannot be repaired and, if faulty or damaged it must be replaced.
REMOVAL
WARNING: Refer to the applicable warnings and cautions for this system before performing the following
operation (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - WARNING) and (refer to 24 - HEATING
& AIR CONDITIONING/PLUMBING - CAUTION). Failure to follow the warnings and cautions could result in
possible personal injury or death.
CAUTION: Before removing the A/C condenser, note the location of each of the radiator/condenser air seals.
These air seals are used to direct air through the A/C condenser and radiator. The air seals must be rein-
stalled in their proper locations in order for the A/C and engine cooling systems to perform as designed.
24 - 134
PLUMBING
PM
1. Disconnect and isolate the negative battery cable.
2. Recover the refrigerant from the refrigerant system
(refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING
-
STANDARD
PROCEDURE
-
REFRIGERANT SYSTEM RECOVERY).
3. If equipped with the 2.2L diesel engine, remove the
front fascia (refer to 13 - FRAME & BUMPERS/
BUMPERS/FRONT FASCIA - REMOVAL).
NOTE: It is not necessary to remove the hood
latch from the upper radiator support on gasoline
engine equipped models for A/C condenser ser-
vice.
4. If equipped with a gasoline engine, remove the
upper radiator support and position it out of the
way (refer to 23 - BODY/EXTERIOR/SUPPORT-
UPPER RADIATOR - REMOVAL).
5. On gasoline engine equipped models, carefully
push the radiator (1) slightly rearward to gain access to the A/C condenser (2).
6. Remove the nut (3) that secures the A/C discharge line (4) to the right side of the A/C condenser and remove
and discard the O-ring seal and gasket.
7. Install plugs in, or tape over the opened discharge line fitting and the condenser inlet port.
NOTE:
Illustration
shown
with
front
fascia
removed for clarity.
8. Raise and support the vehicle.
NOTE: On gasoline engine equipped models,
reach up through the opening in the bottom of the
front fascia located in the right front corner of the
vehicle to gain access to the A/C liquid line.
9. Remove the nut (1) that secures the A/C liquid line
(2) to the right side of the A/C condenser (3).
10. Disconnect the A/C liquid line from the A/C con-
denser and remove and discard the O-ring seal
and gasket.
11. Install plugs in, or tape over the opened liquid line
fitting and the condenser outlet port.
PM
PLUMBING
24 - 135
NOTE: Illustration shown with front fascia and die-
sel
engine
charge
air
cooler
(CAC)
(when
equipped) removed for clarity.
12. Remove the two bolts (3) that secure the lower
condenser brackets to the radiator (5).
13. Lower the vehicle.
14. If equipped, disconnect the automatic transmis-
sion cooler lines (2) from the left side of the A/C
condenser (1) (refer to 7 - COOLING/TRANSMIS-
SION - STANDARD PROCEDURE - TRANSMIS-
SION
COOLER
LINE
QUICK
CONNECT
FITTING).
15. If equipped with the 2.2L diesel engine, remove
the charge air cooler (CAC) (refer to 7 - COOL-
ING/ENGINE/CHARGE
AIR
COOLER
-
REMOVAL).
16. Carefully lift the A/C condenser straight up and
disengage the two upper condenser brackets (4) from the radiator and remove the condenser from the engine
compartment.
INSTALLATION
NOTE: If the A/C condenser is being replaced, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrig-
erant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is
opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system
leak.
NOTE: Illustration shown with front fascia and die-
sel
engine
charge
air
cooler
(CAC)
(when
equipped) removed for clarity.
1. Carefully lower the A/C condenser (1) straight
down in front of the radiator (5) and engage the
upper condenser brackets (4) to the radiator.
2. If equipped with the 2.2L diesel engine, install the
charge air cooler (CAC) (refer to 7 - COOLING/EN-
GINE/CHARGE AIR COOLER - INSTALLATION).
3. If equipped, connect the automatic transmission
cooler lines (2) to the left side of the A/C con-
denser (refer to 7 - COOLING/TRANSMISSION -
STANDARD
PROCEDURE
-
TRANSMISSION
COOLER LINE QUICK CONNECT FITTING).
4. Raise and support the vehicle.
5. Install the two bolts (3) that secure the lower con-
denser brackets to the radiator. Tighten the bolts to
4.5 N·m (40 in. lbs.).
24 - 136
PLUMBING
PM
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